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BEN-COLOURDyeing systems.
2 BEN-COLOUR Dyeing systems.
Dyeing is a very demanding task, as
the quality of dyeing is to a great
extent visible, recognizable by the
human eye. Furthermore, correction of
rejects is rather time consuming and
costly. This makes the dyeing process
one of the most delicate wet finishing
processes.
Benninger’s dyeing technology fully
satisfies these high requirements. As a
competent supplier of a comprehen-
sive range of textile wet finishing
plants we already put emphasis on
the quality requirements of dyeing in
the pretreatment of the fabric, by the
BEN-BLEACH concept and the
BEN-DIMENSA mercerizing range.
With the possibilities of the
BEN-COLOUR machinery and pro-
cesses Benninger offers comprehen-
sive total solutions for continuous
dyeing on the highest technical level.
BEN-COLOURContinuous dyeing technology, all from one supplier
For any continuous or semi-continuous dyeing process in open width, Benninger is your reliable partner. The undisputed high standard of the applied technology, of the design and the workmanship of Benninger’s machinery and plants enable you – our customers – to economically produce best dyeing quality. And this comprehensively, be it CPB-dyeing, PAD-DRY/Thermosol, Pad-Steam, or post-treatment in the washing section.
Dyestuff class Process Fabric 1 DyePad 2 Air Passage 3 Thermray IR-Dryer
4 Thermfix Hotflue
Reactive Dyestuff Cold Pad Batch Cotton
Pad-Dry/Pad-Steam Dyestuff Penetration Pre-Drying Drying
Pad-Steam all in
Pad-Dry Thermofix Dyestuff Alkali Penetration Pre-Drying Drying
Pad-Humidity Control Dyestuff Alkali Penetration Pre-Drying Humidity-fixation
Vat Dyestuff Pad-Dry/Pad-Steam Cotton Dyestuff Penetration Pre-Drying Drying
Pad-Steam (wet/wet)
Sulphur Dyestuff Pad-Steam all in Cotton
Naphtol Dyestuff Pad-Dry Pad Develop Cotton Naphtolate Electric IR-Drying Drying
Reactive Disperse Dyestuff
Pad-Dry
Thermosol
Pad-Steam
Cotton/
Polyester
Dyestuff Penetration Pre-Drying Drying
Vat Disperse Dyestuff Dyestuff Penetration Pre-Drying Drying
Process overview
BEN-COLOUR Dyeing systems. 3
Flexible layout design enables tailormade plants for any dyeing processes, extendable at any timeA DyePad padder station and an
EXTRACTA washing range already are
sufficient for a semi-continuous CPB
dyeing plant for 100% cotton. Further
additional plant elements are however
required for Co/PES or for continuous
processes.
The DyePad padder or a booster for
addition of fixation chemicals and a
REACTA dyeing steamer for fixation
by wet steam method converts the
CPB-plant to a PAD-STEAM dyeing
plant. For Co/PES a PAD-DRY (PAD-
THERMOSOL) dyeing plant is addi-
tionally required, comprising a dry
section with IR-dryer and HOTFLUE
THERMOSOL chambers.
Requirements for continuous dyeing Uniformity of the dyeing
High color fastness
Short through time
Cost efficient process
High efficiency
Flexible plant, suitable for many
processes
Crease-free fabric run
High reproducibility
5 Thermfix Hotflue
6 DyePad 7 Air Passage 8 Booster 9 Reacta-Steamer 10 Extracta
Dyestuff Alkali Batching Rinsing and Soaping
Alkali Steaming Rinsing and Soaping
Dyestuff Alkali Steaming Rinsing and Soaping
Thermofixating Rinsing and Soaping
n Rinsing and Soaping
Reducing Agent Steaming Oxidation and Soaping
Dyestuff Penetration Reducing Agent Steaming Oxidation and Soaping
Dyestuff
Reducing Agent
Steaming Oxidation and Soaping
Dyeing Salt Air passage Rinsing and Soaping
Thermosoling Alkali Steaming Rinsing and Soaping
Thermosoling Reducing Agent Steaming Oxidation and Soaping
4 BEN-COLOUR Dyeing systems.
Versatility of the Küsters S-Roll Owing to its design and construction,
Küsters high efficiency padders meet
all practical requirements for applica-
tion in modern processing.
Different feeding systems, squeezing
roll coverings, trough shapes as well
as expanders and spreaders allow a
variety of woven and knitted goods to
be treated.
A uniform liquor application over the
fabric width, as well as a selective
liquor application to the selvedge –
center – selvedge zone can be easily
set, reproduced and program con-
trolled if required.
This may become necessary owing to
varying absorption capacity, fabric
tension, weft distortion and humidity
(at the beginning of the process) as
well as faults arising in subsequent
processes, like dyestuff migration at
the selvedges during drying.
System benefits The right concept for every kind of
fabric by appropriate roll coverings,
trough design, as well as expanding
and spreading devices
Uniform linear liquor application by
two deflection-controlled rolls
throughout the entire batch
If requested, varied liquors or
chemicals can be applied over the
length and width of the batch and
also programmed via the PLC, by
an adjustable squeezing effect with
one deflection compensating roll
Reproducibility of all dyestuff and
chemical applications
No cambering of the squeeze rollers
Uniform squeezing pressure within
the fabric area including thick and
narrow webs (without selvedge
pressure)
No side-to-center shading, due to
smooth treatment of the selveges
Simple operation and control due
to clear design
Advantages Low energy consumption
Short return on investment
Completely reliable and
maintenance-free
Reduction of setting-up-time
through an automatic quick
cleaning system
Correction diagram
Küsters DyePad
Küsters DyePad
The Küsters DyePad station with its flexible S-Roll Technology can dye woven and knitted goods, in reproducible and premium quality. Moreover the Küsters DyePad offers great flexibility due to the correction potential of the two S-Rollers. This means an attractively priced, simple to operate, reliable and economical Padder station able for diverse handling.
New Küsters S-Roll with double correction potential Greater flexibility for the dye producer
Enhanced reproducibility with elec-
tronic pressure control
New deflection range
Conventional deflection range
Shaft pressure (bar)
Inte
rnal ro
ller
pre
ssure
(b
ar)
BEN-COLOUR Dyeing systems. 5
Küsters S-Roll Technology
Insight of the S-Roll
The deflection-controlled roll for constant resultsKüsters Padders are equipped with
the well-known “Swimming Roll”
(S-Roll) Küsters Technology. With
controlled linear pressure the deflec-
tion-controlled rolls achieve a spe-
cific squeezing nip for every fabric.
Sealing concept of the S-Roll
Pressure reduced at center of rolls
Linear pressure between two S-Rolls
absolutely even across the full width
Pressure increased at center of rolls
Pressure raised on one side of the rolls
Technical data 222.12 222.18
Number of S-Rolls 2 2
Working width (mm) 1600 – 2600 2400 – 3600
Diameter of S-Rolls (mm) 220 300
Max. linear pressure (N/mm) 15 – 50 12 – 50
The S-Roll as the heart of the overall system enables accurate reproducible results due to its user defined capabilities, to define pressure application possibilities to the two S-Rolls. By means of an intelligent software support system, a uniform dyestuff application is guaranteed, this means versatile requirements in relation to quality and material can be achieved.
6 BEN-COLOUR Dyeing systems.
Example for wovens without quick cleaning Example for nip dyeing onlyExample for wovens and knits with
quick cleaning
Padder alternatives and trough shapes
Trough shapesSpecial displacement elements and
lay-on rollers in U-shaped troughs
permit low liquor contents and ac-
cordingly fast liquor exchange.
This also prevents any undesired
changes in the concentration.
Furthermore the low liquor content
has a positive effect on the exchange
of liquor with minimum dyestuff and
chemical loss. All troughs can be
raised and lowered pneumatically.
Roller adjustmentThe application determines the roll
covering, the trough shape and the
expander unit. The possibility of ad-
justing the roller position means that
the new DyePad padder offers abso-
lute flexibility. As a universal core unit,
the DyePad is able to meet all textile
processing challenges.
Nip dyeingBesides this type of trough, the well-
known wedge shaped trough can be
installed for specific applications.
In this case, the fabric is guided from
top to bottom through a horizontal
roller nip. Passing through a trough is
alternatively possible.
Modular design and construction enables all practical requirements for application in modern processing. All concepts are aligned to supply economically and technologically, the best possible solution for our customers.
Dissolving
station
Chemicals
Contidos SF 3
Dye padder
Dye preparation
BEN-COLOUR Dyeing systems. 7
Overview Contidos SF dosing station
Contidos SF dosing station
The Contidos SF dosing station guarantees accurate reproduction at a premium quality as well as consistent process management. The system efficiently controls the entire dyeing process through automatic monitoring and online dosing.
Single component dosing unit
Modern concept for Cold Pad Batch (CPB) reactive dyeingThe complexities of the textile chal-
lenges, require custom-made con-
cepts and innovative detailed solu-
tions, regarding construction and
procedure.
Mastering the CPB reactive dyeing
process goes way beyond the flexing
compensation of the rollers and their
correction possibilities. The target of
the dye producer is to have an accur-
ately reproducible process manage-
ment. This is accomplished by tem-
perature management and innovative
dosing concepts.
Temperature managementSeason and geographically indepen-
dent, constant and reproducible ap-
plication and batching temperature.
Dosing to measure Online dosing for CPB dyeing
with padder
Production of dye liquor on the
basis of dye solution and
auxiliaries dispensed separately
Dye solution and auxiliaries are
blended homogeneously in a mixer
and fed into the padder
Dosing of each individual compo-
nent according to a formula in
ml per liter of dye liquor
Metering of liquor pick-up
Record of consumption
Automatic operation mode
High accuracy in dye liquor pro-
duction, with automatic control of
dosing tolerances
Simple and rapid color changes
Small loss of dye liquor and
short rinsing-times in the case of
color changes
No preparation of auxiliary baths
Dosing capacity according to a reci-
pe and production capacity
PLC control with operator terminal
Link to process control system
Dissolving and preparation unit
available
8 BEN-COLOUR Dyeing systems.
REACTADye steamer
BOOSTER for equal and uniform liquor applicationThe special squeeze nip of the
BOOSTER guarantees a uniform pick-
up, independent from production
speed and fabric weight. Linearity of
the nip line is ensured despite the
freely adjustable nip pressure.
The liquor pick-up can be adjusted
from 70–130%. The economiser
trough with swivelling trough roller is
distinguished by a low liquor volume
of only 14 l/m. Because of the quick
liquor turnover, possible errors in the
initial filling have almost no effect and
deviations over length are avoided.
The displacement body can be pneu-
matically lifted for easy cleaning of the
BOOSTER.
Perfect fixation of dyestuff in the REACTAConstant saturated steam conditions
are the essential prerequisite for per-
fect dyeings and their reproducibility.
Benninger feeds to steam for humidity
control through a steam conditioning
station. Hence, the steam enters the
REACTA dyeing steamer in perfectly
saturated condition. The steamer
design and the positioning of the
steam condition monitoring warrant
absolute absence of air in the stea-
mer. Even minimal deviations lead
immediately to an automatic correc-
tion of the steam feed.
Geometry and drive system of the
REACTA ensures crease free cloth
run. The rollers are with large diam-
eters of 193 mm, and are individually
driven by maintenance free AC-mo-
tors. Very precise drive control is
ensured via load-cell equipped mea-
suring rollers and frequency conver-
ters. Tension differences caused by
shrinking or stretching of the cloth in
the steaming process are equalized
immediately.
The distance from either the DyePad
or the BOOSTER is kept very short for
the dyestuff development. At the entry
of the fabric into the steamer, a lip
heating and an exhaust suction fan for
excess steam prevent condensate
drops at the entry area. The steamer
roof is heated; roof and front and back
side are well insulated. The water lock
at the steamer exit is a critical part of
equipment for a successful process.
The temperature is controlled via the
water feed and low water volume
ensures constant process parameters.
The REACTA steamer has good ac-
cess and can be cleaned easily. An
automatic cleaning device is optio-
nally available.
1 Horizontal or vertical fabric entry with
heated lips and exhaust fan for excess
steam
2 Section with 25 m fabric content
3 Large roller diameter (193 mm) for
creaseless fabric run
4 Lifetime lubricated bearings
5 Top rollers individually driven by AC-motors
6 Load cell to measure fabric tension for
drive control
7 Roof heating
8 Water seal with small liquor content and
uniform liquor distribution
9 Temperature or volume controlled fresh
water flow to the water seal
10 Steam conditioning unit
11 Probe to measure the steam condition
(below steamer bottom level)
12 Automatic cleaning system (option)
Cylindrically ground soft rubber
rollers
Liftable liquor displacement body
Chemical feed distributed over
entire fabric width
BEN-COLOUR Dyeing systems. 9
Bifunctional dye steamer
The dye steamer is the core element
in the PAD-STEAM fixing process for
reactive and vat dyestuffs. But since
the PAD-STEAM dyeing plant is often
employed as a washing machine on
account of flexibility, the dye steamer
has to be bypassed or run through
without functioning. The REACTA
bifunctional Benninger dye steamer
can be flooded, so that if needed it
serves as a fully effective washing
compartment, as for example to pre-
rinse CPB reactive dyeings.
REACTA as washing compartmentThe wash water may be led in coun-
terflow from the following wash com-
partment, or fed via 2 spray pipes into
the water lock. The roller seal is de-
signed so that sealing is assured
equally in steam atmosphere
or flooded state.
Good efficiency and economy from short setting-up timesProduction interruptions caused by
every change in shade or article are
unavoidable in dyeing. Dyeing liquor
must be drained and rinsing baths
must be renewed. In the event of big
differences in shade or deepness even
the entire washing zone with all oxida-
tion and soaping baths may be
drained and prepared again.
Interruption times are minimized with
BEN-COLOUR by following measures
(partly optional) and the economy is
improved:
Large drain and feed pipes on all
washing compartments
Low liquor volume (selection of
EXTRACTA/TRIKOFLEX models
based on process requirements)
Sectional drain within the
washing zone
Automatic emptying and filling
Automatic heating-up cycle
Automatic cleaning device for dye-
ing padder and REACTA steamer
Good accessibility, no dead cor-
ners, large windows, easy opening
covers with hinges and springs, no
pumps
High reproducibility
High processing safety (saturated
steam conditions guaranteed)
Low tension and crease free cloth
run
High efficiency due to bifunctional
usability
Quick machine preparation and
changeovers
Low maintenance and simple
10 BEN-COLOUR Dyeing systems.
BEN-COLOUR
Continuous PAD-STEAM process
Semi-Continuous Process
Continuous PAD-DRY and PAD-STEAM process
padding (1 or 2 baths) steaming oxidation/soaping drying
padding batching rinsing and soaping with immersion store
penetration and IR-predrying Steaming
padding drying and/or
thermofixation
cooling padding
(1 or 2 baths)
BEN-COLOUR Dyeing systems. 11
Continuous PAD-STEAM processThis example shows a small
PAD-STEAM dyeing range. The ad-
vantages of the continuous dyeing
process and the flexibility of a small
size range are here combined!
Possible applications PAD-STEAM process for vat andPAD-STEAM process for vat and
reactive dyestuff (PAD-DRY is car-
ried out in a separate range)
1-bath (all in) PAD-STEAM process1-bath (all in) PAD-STEAM process
with sulfur dyestuff (cotton)
2-bath (wet/wet) PAD-STEAM pro-2-bath (wet/wet) PAD-STEAM pro-
cess vat dyestuff (cotton)
1-bath (all-in) PAD-STEAM process1-bath (all-in) PAD-STEAM process
with reactive dyestuff (cotton)
2-bath (wet/wet) process with direct2-bath (wet/wet) process with direct
dyestuff (cotton)
Continuous PAD-DRY and PAD-STEAM process The range is separated into a PAD-
DRY and a PAD-STEAM part. Both
parts can run separately or in line.
The NW-EXTRACTA washing section
can run separately as well. This range
is optionally equipped with a winding
station for COLD PAD BATCH dyeing.
Possible applications PAD-DRY/PAD-STEAM processPAD-DRY/PAD-STEAM process
with reactive or vat dyestuff (cotton)
PAD-THERMOSOL/PAD-STEAMPAD-THERMOSOL/PAD-STEAM
process with reactive and disperse
dyestuff (cotton/polyester)
PAD-THERMOSOL/PAD-STEAMPAD-THERMOSOL/PAD-STEAM
process with vat and disperse dye-
stuff (cotton/polyester)
PAD-DRY/THERMOFIX processPAD-DRY/THERMOFIX process
with reactive dyestuff (cotton)
PAD-DRY/PAD-DEVELOP processPAD-DRY/PAD-DEVELOP process
with naphtol dyestuff (cotton)
COLD PAD BATCH dyeing processCOLD PAD BATCH dyeing process
with reactive dyestuff (cotton)
rinsing and oxidation/soaping drying
You can feel it’s Benninger
The Swiss company Benninger has been the textile industrys leading partner across the globe for one hundred and fifty years with global branches and service representatives. Benninger develops and manufactures textile finishing and cord production ranges as well as providing complete system solutions. As the market leader Benninger will continue to rely on its comprehensive process know-how in order to be able to offer high-quality installations with excellent customer service.
Head office Uzwil, SwitzerlandSwitzerland
Subsidiaries Mumbai, India
Shanghai, China
Zell, GermanyGermany
Zittau, GermanyGermany
Representative office Moscow, RussiaMoscow, Russia
Benninger AG9240 Uzwil, Switzerland
T +41 71 955 85 85
F +41 71 955 87 47
www.benningergroup.com
Benninger Zell GmbHSchopfheimerstrasse 89
79669 Zell i.W., Germany
T +49 7625 131 0
F +49 7625 131 298
Benninger ZittauKüsters Textile GmbH
Gerhart-Hauptmann-Strasse 15
02763 Zittau, Germany
T +49 3583 83 0
F +49 3585 83 303
Benninger AGMoscow Office
Leningradsky pr-t 72
Bld. 4, Office 802
125315 Moscow, Russia
T +7 495 721 18 99
F +7 495 721 30 84
Benninger India Ltd.415 / 416 & 417
Sunshine Plaza
Dadar (East)
Mumbai 400 014, India
T +91 22 4322 7600
F +91 22 4322 7601
Benninger Textile Machinery Co. Ltd.Room 904, Tower A
City Center of Shanghai
100 Zun Yi Road
Shanghai 200051, P.R. China
T +86 21 6237 1908
F +86 21 6237 1909
Locations